Commander 2006-2007

Intake Manifold

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Removal & Installation



3.7L & 4.7L Engines
  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove the air intake system.
  8.  
  9. Disconnect the throttle and speed control cables.
  10.  
  11. Disconnect the electrical connectors for the following components:

    Manifold Absolute Pressure (MAP) sensor connector
     
    Intake Air Temperature (IAT) sensor connector
     
    Throttle Position (TP) sensor connector
     
    Idle Air Control (IAC) valve connector
     
    Engine Coolant Temperature (ECT) sensor
     

  12.  
  13. Disconnect the following components:

    Positive Crankcase Ventilation (PCV) valve and hose
     
    Canister purge vacuum line
     
    Brake booster vacuum line
     
    Cruise control servo hose
     

  14.  
  15. Remove the alternator.
  16.  
  17. Remove the air conditioning compressor.
  18.  
  19. Disconnect the left and right radio suppressor straps.
  20.  
  21. Disconnect and remove the ignition coil packs.
  22.  
  23. Remove the top oil dipstick tube mounting bolt and ground strap.
  24.  
  25. Remove the fuel rail.
  26.  
  27. Remove the throttle body assembly and mounting bracket.
  28.  
  29. Remove the heater hoses from the engine front cover and heater core.
  30.  
  31. Unclip, then remove the hoses from the intake manifold.
  32.  
  33. Support the engine using Special Tool 8534 Engine Support Fixture.
  34.  
  35. Remove the right side engine mount-to-frame bolt.
  36.  
  37. With the bolt removed, carefully lower the engine until it resets in the frame mount.
  38.  
  39. Remove the intake manifold bolts in the reverse order of the tightening sequence.
  40.  
  41. Remove the intake manifold and gaskets.

    Click image to see an enlarged view

    Fig. Intake manifold bolt torque sequence-3.7L Engine



    Click image to see an enlarged view

    Fig. Intake manifold torque sequence-4.7L engine

  42.  

To install:

  1. Install the intake manifold gaskets.
  2.  
  3. Install the intake manifold and tighten the mounting bolts in the sequence shown to 105 inch lbs. (12 Nm).
  4.  
  5. Install the left and right radio suppressor straps.
  6.  
  7. Install the throttle body assembly.
  8.  
  9. Connect the throttle and speed control cables to the throttle body.
  10.  
  11. Install the fuel rail.
  12.  
  13. Install and connect the ignition coil packs.
  14.  
  15. Position the heater hoses into the clips on the intake manifold, then connect the heater hoses to the heater core and front cover.
  16.  
  17. Connect the electrical connectors for the following components:

    MAP sensor
     
    IAT sensor
     
    TP sensor
     
    IAC valve
     
    ECT sensor
     

  18.  
  19. Install the top oil dipstick mounting bolt and ground strap.
  20.  
  21. Install the alternator.
  22.  
  23. Install the A/C compressor.
  24.  
  25. Connect the following components:

    Positive Crankcase Ventilation (PCV) valve and hose
     
    Canister purge vacuum line
     
    Brake booster vacuum line
     
    Cruise control servo hose
     

  26.  
  27. Raise the engine using the engine support fixture.
  28.  
  29. Install the right side engine mount through bolt and remove the engine support fixture.
  30.  
  31. Install the air intake assembly.
  32.  
  33. Refill the cooling system to the correct level.
  34.  
  35. Connect the negative battery cable.
  36.  
  37. Start the engine and check for leaks.
  38.  

5.7L Engines
  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine appearance cover.
  6.  
  7. Remove the air intake hose.
  8.  
  9. Remove the ignition wires from the top of the intake manifold.
  10.  
  11. Disconnect electrical connectors for the following components:

    Manifold Absolute Pressure (MAP) Sensor
     
    Fuel Injectors
     
    ETC (Electric Throttle Control)
     

  12.  
  13. Remove the wiring harness from the intake manifold.
  14.  
  15. Disconnect brake booster hose, purge hose, and the Make-Up Air (MUA) hose.
  16.  
  17. Remove the EGR tube from the intake manifold.
  18.  
  19. Remove the intake manifold retaining fasteners in a crisscross pattern starting from the outside bolts and ending at the middle bolts.
  20.  
  21. Remove the intake manifold as an assembly.
  22.  

To install:

  1. Position and install the intake manifold. Tighten the retaining bolts in sequence from the middle bolts towards the outside in a crisscross pattern to 105 inch lbs. (12 Nm).
  2.  
  3. Install the EGR rube.
  4.  
  5. Install the wiring harness to the intake manifold.
  6.  
  7. Connect the electrical connectors:

    MAP sensor
     
    Fuel Injectors
     
    ETC
     

  8.  
  9. Install the ignition wires.
  10.  
  11. Connect the brake booster hose, purge hose and MUA hose.
  12.  
  13. Install the air intake hose.
  14.  
  15. Install the engine appearance cover.
  16.  
  17. Connect the negative battery cable.
  18.  

 
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